Key Milestones in TPM Journey for Excellence
Key milestones in the Total Productive Maintenance (TPM) journey for achieving excellence are outlined, including different levels of awards, essential steps, and the significance of CII certificates in fostering continuous improvement in Indian companies.
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'CII CERTIFICATE ASSESSMENT CRITERIA 2023 Page No: 1 CII TPM Club India
KEY MILESTONES - TPM JOURNEY IN A COMPANY THE MODEL for JIPM TPM Excellence Award Or CII-TPM Excellence Award TPM Declaration ~3 to 9 months after Declaration Kick off function Certificate of Strong Commitment for TPM ~1 year after kick off CII TPM Club Certificate of Significant Achievement for TPM ~2 years after kick off India By ~3 years after kick off Diagnostic Assessment 3 years after kick off By JIPM, Japan Jul - Sep Apr - Jul CII First Stage Assessment JIPM First Stage Assessment CII TPM Club Oct - Dec India By CII Second Stage Assessment JIPM Second Stage Assessment Oct - Dec March next Year Receiving Receiving December CII TPM Excellence Award JIPM TPM Excellence Award Page No: 2
DIFFERENT LEVEL JIPM TPM AWARDS Excellence Award 5 Years Consistency Award 2 to 3 Years Special Award 2 to 3 Years Advance Award 2 to 3 Years World Class Award 2 to 3 Years Page No: 3
Stage Step Essential 1. Declaration by top management to introduce TPM Declared in TPM in-house seminar Carried in company magazine Preparations for implementation (3 to 9 months) 2. Introductory education and campaign for TPM Managers : General employees : Seminar meeting using slides Trained in seminar camp at each level 3. Establishing TPM promotion organization Committee and subcommittees Secretary 4. Setting basic principles and target for TPM Bench-mark and target Prediction of effects 5. Creation of master plan for establishing TPM From preparations for introduction to examination Beginning of implementation (1 day) 6. Kick-off of TPM Suppliers Related companies Affiliated companies are invited 7. Establishing systems for improving production efficiency Pursuing maximum efficiency of production Actual implementation (3 years) 7.1 Individual improvement Project team activities and small group activities in the workshop 7.2 Autonomous maintenance Step system, diagnosis and qualification certification 7.3 Planned maintenance Improvement maintenance, periodic maintenance, predictive maintenance 7.4 Group education of leaders and training members Operation and maintenance skills upgrading training 8. Establishing initial control systems for new products and equipment Development of easy-to-manufacture products and easy-to-operate equipment 9. Establishing quality maintenance organization Setting conditions without defectives, and its maintenance and control 10. Establishing systems to improve efficiency of administration and other indirect departments Support for production, increasing efficiency in the department and of equipment 11. Establishing systems to control safety, sanitation and working environments Establishing zero accidents and zero pollution systems Steady application (15) 12. Total application of TPM and raising its level Application of PM award Challenge of a higher target Page No: 4
Why CII Certificates & awards? Over 3000 Indian companies have started JIPM-TPM implementation to become competitive and also to get recognition. JIPM confers companies with TPM excellence award only in 5th year in TPM implementation journey. There is no way for the companies to find out the progress status or get any recognition so around 90% of them quit in between CII TPM Club India has designed an evaluation mechanism and created Mile stones at regular intervals in the long journey to motivate the companies to continue TPM journey and get benefited for long period. The companies can complete the pre decided portion, get tangible benefits and also challenge CII TPM Club India to get recognition after successful adherence of the evaluation criteria. The evaluations will also be useful for companies who are planning to apply for Diagnostic assessment and JIPM TPM Excellence Awards. Page No: 5
Award for Excellence in Operational Technology (EOT) Award for Excellence in Operational Technology Must have minimum of 3 years of TPM practice after the TPM Kick off or after completion of one year in CII TPM Significant achievement certification are eligible to apply. In this EOT Category, TPM activity must be implemented at plants / factories on 8 pillars (individual improvement; autonomous maintenance; planned maintenance; initial management; quality maintenance; administrative and supervisory department; education and development; safety, Health, and environment control). Important to note that plants / factories must be completed the 4th Step of Autonomous Maintenance (Jishu - Hozen) at least by minimum 75% of equipment completed the 4th Step. The phrase completion of the 4th step" regarding Autonomous Maintenance means that each operator has understood the functions and structures of the equipment in their workplaces to prevent losses. Must have completed infrastructure development for TPM activity with both tangible and intangible achievements obtained. Preliminary Audit & Final audit are there. The guidelines /home works given in first stage audit to be presented along with other improvements in final audit. Page No: 6
1) Certificate of Strong Commitment for TPM Eligibility Criteria For companies Medium and Large Page No: 7
1) Eligibility Criteria for Certificate of Strong Commitment for TPMFor Medium and Large Industries Must have completed the 5 Steps of Preparation phase (1.Top Management Declaration, 2.Training & Campaign, 3.Promotion Organization, 4.Targets, 5.Master plan), have done TPM Kick off . Must have completed approximately one year of TPM implementation activity after the Kick off. Must have completed 1S and 2S in entire Shop floor and Office area Must have deployed activity on 25 to 30% of total machines by numbers in the organization. 4 pillars of TPM (Focused improvement - one phase; Autonomous maintenance Step3 ; Planned maintenance- Step3; Quality maintenance- Step4) should be Implemented and other 4 pillars (ET, DM, OTPM and SHE) must be initiated Must have completed Step 3 of Autonomous maintenance activity on 25 to 30% machine and initiated Step 4 on those machines Circle member operators. Must have achieved both Tangible (Productivity, Quality, Cost, Delivery, Safety & Morale) and Intangible achievements based on Result Criteria. Mainly - No fatal accident in last one year, Plant level 25% reduction in Breakdown frequency & Defect Quantity are essential results Page No: 8
2 Certificate of Significant Achievement for TPM Eligibility Criteria For companies Medium and Large Industries Page No: 9 CII TPM Club India
2 )Eligibility Criteria Certificate of Significant Achievement for TPM for Medium and Large Industries Must have completed 1 year after achieving Certificate of Strong Commitment for TPM, Category A OR approximately 2 year of the activity completed after the TPM Kick-off Must have deployed activity based on 8 pillars of TPM by all staff members of the plants/factories (Focused improvement; Autonomous maintenance; Planned maintenance; Quality maintenance; Development Management, Education and development; Office TPM, Safety, sanitation and environment control) Must have completed Step 3 of Autonomous maintenance activity in at least 60% of Machines by numbers and have implemented Step 4 in 20% Machines. At least 2 phases of Focused Improvement implementation completed and Loss Elimination/ Reduction projects & Kaizen are implemented in sufficient machines/ lines. Must have completed up to Step 4 of Planned Maintenance and Quality maintenance activities in 60% of Machines by numbers and good progress is observed. Other 4 pillars should also have good progress. At least 60% of journey according to master plan should be completed. Must have achieved both Tangible (Productivity, Quality, Cost, Delivery, Safety, Morale) and Intangible achievements based on Result Criteria. Mainly - No fatal accident in last one year, Plant level 50% reduction in Breakdown frequency & Defect numbers are essential results. Good OEE increase and cost reduction Page No: 10 CII TPM Club India
Contents for assessment of both Certificates Criteria for companies with Medium and Large Industries S No. Name Certificate of Strong Commitment Both Company and Plant outline to be presented e.g. Establishment, Employees, Assets, Turn over, Products, Customers Certificate of Significant Achievement Both Company and Plant outline to be presented e.g. Establishment, Employees, Assets, Turn over, Products, Customers Company & Plant Outline 1 TPM policies are planned in relation between company Vision and plant/factory policy. TPM policies are planned in relation between company Vision and plant/factory policy. The relation between TPM target (PQCDSM) values and management target results are clear. KMI-KPI-KAI relationship TPM Policy & Objective The TPM target KMI-KPI (PQCDSM) values are clear. The master plan is in an appropriate order as an action plan to achieve TPM goal. TPM policies and objectives have been set forth and deployed by all the departments and sections in 50- 60% machines. The action plan to achieve TPM goals is clear. 2 TPM objectives have been set forth and deployed in 25- 30% machines. The achievement status of TPM objectives is available in a time line using objective data (Visual Displays). The achievement status of TPM objectives is available in a time line using objective data (Visual Displays). Organization & Overlapping small groups, the TPM promotion committee, and other special committees are organized to leads TPM activities. Overlapping small groups, the TPM promotion committee, and other special committees are organized to leads TPM activities. Activity TPM 3 The organization structure is created for effective implementation of TPM and TPM Circles are active. The organization structure is created for effective implementation of TPM and TPM Circles are active. Page No: 11 CII TPM Club India
Contents for assessment of both Certificates Criteria for companies with Medium and Large Industries S No Name Certificate of Strong Commitment Certificate of Significant Achievement Pillar KPI targets are set inline with company target Individual improvement themes are set for critical machines / lines along with clear targets. Individual improvement Objectives (KAIs) are set for major Losses in Critical machines and contributions are observed by performance indexes (KPIs). Improvement activities in critical machines / lines are being actively carried out for top 4 losses of KK and contribution to the achievement index is clearly understood One cycle of project implementation (7step KK approach) A system to apply cases of individual improvement horizontally is initiated. Pillar KPI targets are set inline with company target Individual improvement themes are set for critical machines / lines along with clear targets Individual improvement Objectives (KAIs) are set forth for each Loss in all departments and contributions are observed by performance indexes (KPIs). A system is set up to analyze and understand the relationship between loss and cost using the loss tree, cost tree and cost lost matrix / relationship. Improvement activities in critical machines / lines are being actively carried out for top 4 losses of KK and contribution to the achievement index is clearly understood Multiple cycle of project implementation A system to apply cases of individual improvement horizontally is established. Individual Improvement 4 Page No: 12 CII TPM Club India
Contents for assessment of both Certificates Criteria for companies with Medium and Large Industries S No Name Certificate of Strong Commitment Pillar KPI targets are set inline with company target TPM Circle formation, Zone formation, 1S-2S Implementation in all zones Autonomous maintenance Step1,2 & 3 implementation plan is there and is deployed in 25- 30% critical machines. Workplace/on-site visual boards, which show the status of activities, goals, accomplishments, and issues to be resolved, are in place. Actions are being taken to remove all abnormalities and to eliminate their cause. Cleaning, lubrication, bolt tightening, and inspection are performed perfectly and without fail, and thorough measures are taken for difficult-to-handle areas. Excellent storage procedures are in effect for tools and jigs, and cleaning is carried for critical areas. One-point lessons are available as training texts and are being used. Certificate of Significant Achievement Pillar KPI targets are set inline with company target Autonomous maintenance Step1,2 & 3 implementation plan is there and is deployed in 50-60% machines. Workplace/on-site visual boards, which show the status of activities, goals, accomplishments, and issues to be resolved, are in place. Actions are being taken to remove all abnormalities and to eliminate their cause. Cleaning, lubrication, bolt tightening, and inspection are performed perfectly and without fail, and thorough measures are taken for difficult-to-handle areas. Achievement goals are appropriately assessed at each step by managers for progress and completion. Excellent storage procedures are in effect for tools and jigs, and cleaning is carried out routinely. One-point lessons are available as training texts and are being used Step 4 is in place for more machines Employee morale surveys and skill maps are used to confirm that all employees are working on workplace improvement with a sense of accomplishment. A system to upgrade the skills of all employees is established and deployed with a skill evaluation chart, one- point lessons, and maintenance skill training, and is showing results. Autonomous Improvement 5 Page No: 13 CII TPM Club India
Contents for assessment of both Certificates Criteria for companies with Medium and Large Industries S No Name Certificate of Strong Commitment Pillar KPI targets are set inline with company target Breakdown Elimination targets are set for and is being deployed in 25-30% machines Support for autonomous maintenance is provided. Steps 1,2,3 of 7 step PM should be implemented in 25- 30% critical machines. Sudden breakdown has significantly decreased with thorough failure analysis and enhanced improvement maintenance in 25-30% critical machines. Maintenance standards are in order and an appropriate maintenance calendar is created for critical machines. Maintenance information on the status of equipment deterioration, failure, equipment shutdown, maintenance man-hours, etc. is collected and utilized. Methods for maintenance cost and lubrication management is present and is practised. Certificate of Significant Achievement Planned maintenance KPIs & KAIs are set up in line with TPM policies and is being deployed in 50-60% machines. Support for autonomous maintenance is provided and a mutual cooperative structure is established. Sudden breakdown has significantly decreased with thorough failure analysis and enhanced improvement maintenance; a system is set up for MP design information to accumulate and utilize the data. Maintenance standards are in order and an appropriate maintenance calendar is created and followed. Appropriate equipment diagnosis technologies are being put to use for predictive maintenance and deterioration checks, and TBM (time-based maintenance) and CBM (condition-based maintenance) are selectively used. A system is initiated for professional maintenance skills such as repair skills, inspection skills, lubrication control skills, and failure analysis skills, for which a sufficient technical level has been reached. Spare parts, molds jigs, fixtures, measuring equipment, drawings, etc. are all stored as data. Maintenance information on the status of equipment deterioration, failure, equipment shutdown, maintenance man-hours, etc. is collected and utilized. Methods for maintenance cost and lubrication management is present and is practised. Planned Maintenance 6 Page No: 14 CII TPM Club India
Contents for assessment of both Certificates Criteria for companies with Medium and Large Industries S No. Name Certificate of Strong Commitment Pillar KPI targets are set inline with company target Defect Elimination targets are set for and is being deployed in 25-30% machines Data are being accumulated for defect outflow and defect process, causes are being analyzed, and improvement goals are being set up. For quality defects, measures are taken to prevent recurrence from the aspect of 4M for major defects in critical machines/areas. Based on fundamentals and principles, quality defects are being analyzed for cause in critical machines. Measures aiming for zero occurrences of quality defects are showing results by implementation up to step 4 of 10 Step QM methodology. Methodology for capturing customer complaints is in place and is being addressed Certificate of Significant Achievement KPIs & KAIs for quality maintenance are set up in line with TPM policies and is being deployed in 50-60%. Data are being accumulated for defect outflow and defect process, causes are being analyzed, and improvement goals are being set up. For quality defects, measures are taken to prevent recurrence from the aspect of 4M. Based on fundamentals and principles, quality defects are being analyzed for cause. Measures aiming for zero occurrences of quality defects are showing results by implementation of 10 Step QM methodology.. Methodology for capturing customer complaints is in place and is being addressed Quality Maintenance 7 Page No: 15 CII TPM Club India
Contents for assessment of both Certificates Criteria for companies with Medium and Large Industries S No. Name Certificate of Strong Commitment Pillar KPI targets are set inline with company target The MP design approach and the implementation of equipment, molds, jigs, and fixtures are both initiated in critical machine. The concept of cost review is in place and is being practiced. Certificate of Significant Achievement DM KPIs & KAIs are set up in line with TPM policies. In product and machine / plant development management, a system that extracts the origin of problems in design review and debugging is initiated. The concept of cost review is in place and is being practiced. The MP design approach and the implementation of equipment, molds, jigs, and fixtures are both initiated. A design method based on assessment standards for ease of production is introduced. Development Management 8 Pillar KPI targets are set inline with company target CFT members are trained on required knowledge and Skill to perform the TPM task on Critical machines. Skill evaluation and enhancement plan is made and standards and Module preparation initiated KPIs &KAIs are covering the requirements of the organisation. A systematic training program for each job and rank is established with employees having understanding of the required knowledge and skills for each job and rank. A place for maintenance skill training is provided and utilized for professional maintenance training and operator training, making it possible to carry on the skills. OJT training programs are functioning leading to the upgrading of skills for all staff members and progress in multi-skilled worker training. Employee satisfaction and the status of motivation are quantitatively analyzed and measures are in place for their enhancement. Education & Training 9 Page No: 16 CII TPM Club India
Contents for assessment of both Certificates Criteria for companies with Medium and Large Industries S No. Name Certificate of Strong Commitment Certificate of Significant Achievement Pillar KPI targets are set inline with company target Improvement project in office area is also initiated to reduce Management loss and inventory 5S is in progress in office area, all Stores and Scrap yard. Searching eliminated and Retrieval time is drastically reduced. KPI & KAI for Office TPM is set 5S is in progress in office area, all Stores and Scrap yard. Searching eliminated and Retrieval time is drastically reduced. The improvements to reduce product inventory and goods in process is in progress. Morale is being enhanced in the administrative and supervisory departments. Each department is dealing with reducing costs incurred from operations and overall cost reduction is improving. KPI & KAI for Safety, Health and Environment is set Past cases of accidents and plant disasters have been scientifically analyzed, and action has been taken to prevent recurrence. Safety awareness improvement activities take place regularly with near accident, KY and other measures. Safety devices such as safety covers, safety nets, safety signage, and foolproof disaster prevention measures are appropriately prepared. Plant level KPI result in PQCDSM to be achieved as per plant targets, Specially Breakdown, Defects are achieved by 50% reduction Results in 50-60% machines should be achieved according to plan Office TPM 10 Pillar KPI targets are set inline with company target Safety measures are initiated Safety, Health & Environment 11 Plant level KPI results should be achieved. Specially Breakdown, Defects are achieved by 25-30% reduction Results in 25-30% machines should be achieved according to plan 12 Results Page No: 17 CII TPM Club India
1 Certificate of Strong Commitment for TPM SCORE SHEETS Page No: 18 (C) 2015 CII TPM Club India
1000 point Assessment Scoring sheet 1) Certificate of Strong Commitment for TPM SUMMARY SHEET Sl No Excel- lent Audit Parameter Max Score Poor Low Fair Good Involvement of Top Management & Employees and Understanding & Implementation of 'Preparatory steps' 41- 80 81- 120 121- 160 161- 200 A 200 0-40 Implementation of 4 Pillar activities' and Quality of Presentations in Schedule A (Off Site) 41- 80 81- 125 126- 170 171- 200 B 200 0-40 Implementation of 4 Pillar activities' and Quality of Stories Presentations in Schedule B (On Site) 41- 80 81- 125 126- 170 171- 200 C 200 0-40 66- 130 131- 220 221- 315 36- 400 D Overall Results & Benefits Achieved by the Activity 400 0-65 Total 1000 NOTE ON SCORING STATUS Please refer further Sheet s for scoring guide line Company should score minimum of 700 points to receive the certificate Page No: 19 (C) 2015 CII TPM Club India
1. Certificate of Strong Commitment for TPM Scoring Criteria Sl. No A : Involvement of Top Management & Employees and Understanding & Implementation of 'Preparatory steps' (Total Score 200) Excel -lent Max Score Poor Low Fair Good Sl No Audit Parameter Corporate / Plant Top Management Involvement, Strategic Planning, Communication/ reviews, active participation, timely support provision and Reward & Recognition 11- 20 21- 30 31- 40 41- 50 A.1 50 0-10 Involvement of Managers, Associates, Proactive Attitudes, Positive Body Language , High Morale and Clarity of their roles & responsibility 11- 20 21- 30 31- 40 41- 50 A.2 50 0-10 Implementation of Manager s Model Machine, Training & Campaign and Formation of Promotion Organisation. 11- 20 21- 30 31- 40 41- 50 A.3 50 0-10 Development, Understanding, Communication and Visual displays of TPM Policy, Logo, Objectives, Targets & Master Plan and doing Kick off' and Adherence to Activity plan 11- 20 21- 30 31- 40 41- 50 A.4 50 0-10 Total 200 POOR LOW FAIR GOOD : Only few Managers & Associates are aware & involved and their involvement is hardly observed : Approximately 30% Managers & Associates are aware & involved and Top management also reviews some time : Approximately 50% Managers & Associates are aware & involved and Plant Top management also reviews activity : Plant Top management & Approximately 70% Managers & Employees are seriously involved in Activities at respective positions and Visually displayed EXCELLENT : Both Corporate & Plant Top management and 90% Managers & Employees are seriously involved in Activities at respective positions and Visually displayed Page No: 20 (C) 2015 CII TPM Club India
1. Certificate of Strong Commitment for TPM Scoring Criteria Sl. No B : Implementation of 4 Pillar activities' and Quality of Presentations in Schedule A (Off Site) ' (Total Score 200) Sl No Excel -lent Audit Parameter Max Score Poor Low Fair Good Top Management presentation of Chapter 1, 2, 3 & 12 are explicit, clear and covers complete scope B.1 45 0-10 11-20 21-30 30-40 40-45 Focused Improvement is clearly understood and thoroughly implemented for improving Productivity & Cost B.2 45 0-10 11-20 21-30 30-40 40-45 Autonomous Maintenance is clearly understood and Step3 implemented for 15-20% machines & Step4 initiated B.3 45 0-10 11-20 21-30 30-40 40-45 Planned Maintenance do complete Restoration, inspection and repair, TBM and corrective maintenance and Kaizens implemented for Elimination of Breakdown B.4 35 0-5 6-10 11-20 21-30 31-35 Quality Maintenance is implemented up to Step4 for 15-20% machines and Kaizens implemented for Elimination of Breakdown B.5 30 0-5 6-10 11-20 21-25 26-30 Total 200 : Only few Improvement activities done in machines & First 4 Pillars Activities are implemented less than Step3 and other Pillars are not initiated : Improvement activities done in 5% machines & First 4 Pillars Activities are implemented up to Step3 and other Pillars are Initiated partially : Stepwise/ phase wise progress done in 15% machines & First 4 Pillars Activities are implemented between Step3&4 and other Pillars are Initiated : Stepwise/ phase wise progress done in 20% machines & First 4 Pillars Activities are implemented up to Step4 and other Pillars are Matured EXCELLENT : Stepwise/ phase wise progress done in more than 20% machines & First 4 Pillars Activities are implemented beyond Step4 and other Pillars Established POOR LOW FAIR GOOD Page No: 21 (C) 2015 CII TPM Club India
1.Certificate of Strong Commitment for TPM Scoring Criteria Sl. No C : Implementation of 4 Pillar activities' and Quality of Story Presentations in Schedule B (On Site) Excel -lent Sl No Audit Parameter Max Score Poor Low Fair Good Status of 1S, 2S and Visual Display in Shop floor. Maintenance of General condition of Machines, Building and other Infrastructure. Body language of people. 11- 20 21- 30 31- 40 41- 50 C.1 50 0-10 Quality of Story Kaizens & their Presentation for Implementation of Autonomous Maintenance Steps 1,2,3 11- 20 21- 35 36- 50 51- 60 C.2 60 0-10 Quality of Story Kaizens & their Presentation for Focused Improvement for reduction of Loses related to Productivity & Cost 11- 15 16- 20 21- 25 26- 30 C.3 30 0-10 Quality of Story Kaizens & their Presentation for Planned Maintenance for Elimination of Breakdown 11- 15 16- 20 21- 25 26- 30 C.4 30 0-10 Quality of Story Kaizens & their Presentation Quality Maintenance for Elimination of Defects 11- 15 16- 20 21- 25 26- 30 C.5 30 0-10 Total 200 POOR LOW FAIR : 1S, 2S is initiated. AM Steps less than 3 achieved & presented only in MMM : 1S, 2S is Matured. AM Steps up to 3 achieved & presented only in MMM & their Story Kaizens for FI, PM ,QM presented : 1S, 2S is Matured & Visual Management initiated. AM Steps up to 3 achieved & presented in 15% machines. Story Kaizens for FI, PM ,QM presented : 1S, 2S & Visual Management is Matured, AM Steps up to 3 achieved & presented in 20% machines. Story Kaizens for FI, PM ,QM nicely presented EXCELLENT : 1S, 2S & Visual Management is Established, AM Steps up to 3 achieved & presented in more than 20% machines. Story Kaizens for FI, PM ,QM, nicely presented and also OTPM, SHE, DM, E&T presented GOOD Page No: 22 (C) 2015 CII TPM Club India
1.Certificate of Strong Commitment for TPM Scoring Criteria Sl. No D : Overall Results & Benefits Achieved by the Activity Excel -lent 51-60 Max Score Poor Low Fair Good Sl No Audit Parameter D.1 Overall- KMI improvement Results 60 0-10 11-20 21-35 36-50 P - 'Production & Productivity' Increase of 'Equipments & Man' (OEE, Production per Man hour, Other Losses reduction Results) D.2 50 0-10 11-20 21-30 31-40 41-50 D.3 P - Breakdown elimination 40 0-5 6-10 11-20 21-30 31-40 D.4 Q - Customer Complaints elimination 40 0-5 6-10 11-20 21-30 31-40 D.5 Q - In-house Defect elimination 40 0-5 6-10 11-20 21-30 31-40 D.6 C - Manufacturing Cost reduction & Inventory reduction 40 0-5 6-10 11-20 21-30 31-40 D.7 D - Customer Delivery Adherence 30 0-5 6-10 11-15 16-25 26-30 D.8 S Accident elimination 50 0-10 11-20 21-30 31-40 41-50 D.9 M No. of Suggestion, Kaizen per Man per Month 50 0-10 11-20 21-30 31-40 41-50 Total 400 All Results should be seen in 15-20% machine basis POOR LOW : The results achieved at MMM level as P=>10%, Breakdown => 40%, Q=> 40%, C=> 5%, D=>80%, S=>70% & M => 1.5 times from Declaration level data FAIR : The results achieved at Plant level as OA=10%, P=>10%, Breakdown => 40%, Q=> 40%, C=> 5%, D=>80%, S=>70% & M => 1.5 times from Kick off level data GOOD : The results achieved at Plant level as OA=15%, P=>20%, Breakdown => 50%, Q=> 50%, C=> 10%, D=>90%, S=>80% & M => 2 times from Kick off level data EXCELLENT : The results achieved at Plant level as OA=20%, P=>30%, Breakdown => 60%, Q=> 60%, C=> 15%, D=>95%, S=>90% & M => 3 times from Kick off level data : Only Little or NO improvement observed in the results of P, Q, C, D, S, M from Declaration level data Page No: 23 (C) 2015 CII TPM Club India
2 Certificate of Significant Achievement for TPM SCORE SHEETS Page No: 24 (C) 2015 CII TPM Club India
1000 point Assessment Scoring sheet 2. Certificate of Significant Achievement for TPM SUMMARY SHEET Excel- lent Sl No Audit Parameter Max Score Poor Low Fair Good Involvement of Top Management & Employees and Understanding & Implementation of 'Preparatory steps' 41- 80 81- 120 121- 160 161- 200 A 200 0-40 Implementation of 4 Pillar activities' and Quality of Presentations in Schedule A (Off Site) 41- 80 81- 125 126- 170 171- 200 B 200 0-40 Implementation of 4 Pillar activities' and Quality of Stories Presentations in Schedule B (On Site) 41- 80 81- 125 126- 170 171- 200 C 200 0-40 66- 130 131- 20 221- 315 36- 400 D Overall Results & Benefits Achieved by the Activity 400 0-65 Total 1000 NOTE ON SCORING STATUS Please refer further Sheet s for scoring guide line Company should score minimum of 700 points to receive the certificate Page No: 25 (C) 2015 CII TPM Club India
2 Certificate of Significant Achievement for TPM Scoring Criteria Sl. No A : Involvement of Top Management & Employees and Understanding & Implementation of 'Preparatory steps' (Total Score 200) Excel -lent Max Score Poor Low Fair Good Sl No Audit Parameter Corporate / Plant Top Management Involvement, Strategic Planning, Communication/ reviews, active participation, timely support provision and Reward & Recognition 11- 20 21- 30 31- 40 41- 50 A.1 50 0-10 Involvement of Managers, Associates, Proactive Attitudes, Positive Body Language , High Morale and Clarity of their roles & responsibility 11- 20 21- 30 31- 40 41- 50 A.2 50 0-10 Implementation of Manager s Model Machine, Training & Campaign and Formation of Promotion Organisation. 11- 20 21- 30 31- 40 41- 50 A.3 50 0-10 Development, Understanding, Communication and Visual displays of TPM Policy, Logo, Objectives, Targets & Master Plan and doing Kick off' and Adherence to Activity plan 11- 20 21- 30 31- 40 41- 50 A.4 50 0-10 Total 200 POOR LOW FAIR GOOD : Only few Managers & Associates are aware & involved and their involvement is hardly observed : Approximately 30% Managers & Associates are aware & involved and Top management also reviews some time : Approximately 50% Managers & Associates are aware & involved and Plant Top management also reviews activity : Plant Top management & Approximately 70% Managers & Employees are seriously involved in Activities at respective positions and Visually displayed EXCELLENT : Both Corporate & Plant Top management and 90% Managers & Employees are seriously involved in Activities at respective positions and Visually displayed Page No: 26 (C) 2015 CII TPM Club India
2 Certificate of Significant Achievement for TPM Scoring Criteria Sl. No B : Implementation of 4 Pillar activities' and Quality of Presentations in Schedule A (Off Site) ' (Total Score 200) Sl No Excel -lent Audit Parameter Max Score Poor Low Fair Good Top Management presentation of Chapter 1, 2, 3 & 12 are explicit, clear and covers complete scope B.1 45 0-10 11-20 21-30 30-40 40-45 Focused Improvement is clearly understood and thoroughly implemented for improving Productivity & Cost B.2 45 0-10 11-20 21-30 30-40 40-45 Autonomous Maintenance is clearly understood and Step3 implemented for 50% machines & Step4 initiated B.3 45 0-10 11-20 21-30 30-40 40-45 Planned Maintenance do complete Restoration, inspection and repair, TBM and corrective maintenance and Kaizens implemented for Elimination of Breakdown B.4 35 0-5 6-10 11-20 21-30 31-35 Quality Maintenance is implemented up to Step4 for 50% machines and Kaizens implemented for Elimination of defects B.5 30 0-5 6-10 11-20 21-25 26-30 Total 200 POOR : Only few Improvement activities done in machines & First 4 Pillars Activities are implemented less than Step3 and other Pillars are not initiated : Improvement activities done in 25% machines & First 4 Pillars Activities are implemented up to Step3 and other Pillars are Initiated partially : Stepwise/ phase wise progress done in 40% machines & First 4 Pillars Activities are implemented between Step3&4 and other Pillars are Initiated : Stepwise/ phase wise progress done in 50% machines & First 4 Pillars Activities are implemented up to Step4 and other Pillars are Matured EXCELLENT : Stepwise/ phase wise progress done in more than 50% machines & First 4 Pillars Activities are implemented beyond Step4 and other Pillars Established LOW FAIR GOOD Page No: 27 (C) 2015 CII TPM Club India
2 Certificate of Significant Achievement for TPM Scoring Criteria Sl. No C : Implementation of 4 Pillar activities' and Quality of Story Presentations in Schedule B (On Site) Excel -lent Sl No Audit Parameter Max Score Poor Low Fair Good Status of 1S, 2S and Visual Display in Shop floor. Maintenance of General condition of Machines, Building and other Infrastructure. Body language of people. 11- 20 21- 30 31- 40 41- 50 C.1 50 0-10 Quality of Story Kaizens & their Presentation for Implementation of Autonomous Maintenance Steps 1,2,3 and 4 11- 20 21- 35 36- 50 51- 60 C.2 60 0-10 Quality of Story Kaizens & their Presentation for Focused Improvement for reduction of Loses related to Productivity & Cost 11- 15 16- 20 21- 25 26- 30 C.3 30 0-10 Quality of Story Kaizens & their Presentation for Planned Maintenance for Elimination of Breakdown 11- 15 16- 20 21- 25 26- 30 C.4 30 0-10 Quality of Story Kaizens & their Presentation Quality Maintenance for Elimination of Defects 11- 15 16- 20 21- 25 26- 30 C.5 30 0-10 Total 200 POOR LOW FAIR GOOD : 1S, 2S is initiated. AM Steps less than 3 achieved & presented only in MMM : 1S, 2S is Matured. AM Steps up to 3 achieved & presented only in MMM & their Story Kaizens for FI, PM ,QM presented : 1S, 2S is Matured & Visual Management initiated. AM Steps up to 3 achieved & presented. Story Kaizens for FI, PM ,QM presented : 1S, 2S & Visual Management is Matured, AM Steps up to 4 achieved & presented. Story Kaizens for FI, PM ,QM nicely presented also OTPM, SHE, DM, E&T EXCELLENT : 1S, 2S & Visual Management is Established, AM Steps up to 4 achieved & presented. Story Kaizens for FI, PM ,QM, OTPM, SHE, , E&T nicely presented Page No: 28 (C) 2015 CII TPM Club India
2 Certificate of Significant Achievement for TPM Scoring Criteria Sl. No D : Overall Results & Benefits Achieved by the Activity Excel -lent 51-60 Max Score Poor Low Fair Good Sl No Audit Parameter D.1 Overall- KMI improvement Results 60 0-10 11-20 21-35 36-50 P - 'Production & Productivity' Increase of 'Equipments & Man' (OEE, Production per Man hour, Other Losses reduction Results) D.2 50 0-10 11-20 21-30 31-40 41-50 D.3 P - Breakdown elimination 40 0-5 6-10 11-20 21-30 31-40 D.4 Q - Customer Complaints elimination 40 0-5 6-10 11-20 21-30 31-40 D.5 Q - In-house Defect elimination 40 0-5 6-10 11-20 21-30 31-40 D.6 C - Manufacturing Cost reduction & Inventory reduction 40 0-5 6-10 11-20 21-30 31-40 D.7 D - Customer Delivery Adherence 30 0-5 6-10 11-15 16-25 26-30 D.8 S Accident elimination 50 0-10 11-20 21-30 31-40 41-50 D.9 M No. of Suggestion, Kaizen per Man per Month 50 0-10 11-20 21-30 31-40 41-50 Total 400 POOR LOW : Only Little improvement observed in the results of P, Q, C, D, S, S, M & BAD fro Declaration level data : The results achieved at MMM level as P=>10%, Breakdown => 40%, Q=> 40%, C=> 5%, D=>80%, S=>70% & M => 1.5 times from Declaration level data : The results achieved at Plant level as OA=10%, P=>10%, Breakdown => 40%, Q=> 40%, C=> 5%, D=>80%, S=>70% & M => 1.5 times from Kick off level data : The results achieved at Plant level as OA=15%, P=>20%, Breakdown => 50%, Q=> 50%, C=> 10%, D=>90%, S=>80% & M => 2 times from Kick off level data EXCELLENT : The results achieved at Plant level as OA=20%, P=>30%, Breakdown => 60%, Q=> 60%, C=> 15%, D=>95%, S=>90% & M => 3 times from Kick off level data FAIR GOOD Page No: 29 (C) 2015 CII TPM Club India
Fee structure for CII Certificates & Awards Strong Commitment Certificate 1.4 Lakhs Significant Achievement Certificate 1.6 Lakhs Health Check 1.8 lakhs EOT Award 4 lakhs Page No: 30 CII TPM Club India
The assessments and award distribution for the year 2023. Assessments will be done upto first week of September 23 Certification will be distributed in September 23 in TPM National conference. Page No: 31 CII TPM Club India
Address TPM Club India CII Institute of Quality Near Bharat Nagara, IInd Stage, Magadi Main Road, Vishwaneedam Post Bangalore - 560 091 Ph: 080-23289391, 23286085 Website: www.cii.in; www.cii-iq.in; www.tpmclubindia.org Contact Details Mr. Sudarsan Mobile : 9972711066 sudarsan@cii.in Mr. Mani kumar Mobile: 9738227462 mani.kumar@cii.in Mr. L. Ganapathy Subramanian mobile : 9611199588 ganapathy.Subramanian@cii.in Page No: 32 CII TPM Club India
